In this tutorial Poclain Academy will show you stepbystep how to remove a clip and insert a clip in a cylinder block.

For this process you will need the following tools:

• Clip mounting tool
• Inertial extraction tool
• Clip extractor

Remember – tool size depends on the clip and piston size.

Clip Removal

Step 1) Choose the appropriate tool to remove the clip
Step 2) Insert the tool in the clip hole and lightly push downwards or upwards
Step 3) Using the inertial extractor, remove it, avoiding any damage
– the goal is to reach the end of the clip hole by pushing downwards or upwards to lock it and be able to remove it.
The clip automatically needs to be scrapped. Do not reuse it!

Piston Checking and Pin Mounting

Step 1) Once the clip has been removed, pull out the piston block
Step 2) Check all parts for specification conformity: the bushing, the roller, the lunambules, and the piston ring
Step 3) Once the parts have been cleaned and checked, put oil all around the piston hole before mounting
Step 4) oil the piston and the bushing
Step 5) put the roller in the piston and the lunambules on each side
Step 6) insert the piston block assembly in its hole
Step 7) ensure the piston is parallel to the cam ring
Step 8) using the appropriate tool, test the piston without a clip. Once it is possible to push the tool in the clip hole, it means that the piston is parallel to the cam ring. This avoids damaging the tooling or clip, as well as creating waste.
Step 9) Remove the tool and put in a NEW clip by gently inserting it in its hole.
Step 10) take the insertion tool and carefully pull it to its initial position.
Step 11) Take a mallet and hit the insertion tool. Once the tool is inserted at the maximum position, the clip is in and correctly mounted.
Note: Never directly hit the clip with a hammer or mallet!
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